The Bronze Process
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Wax Spruing and Gating, and the Investment Process 

Solid wax bars of different thicknesses, called "Vents" and "Gates",  are attached to the wax with a soldering like tool. Connected on the top is a wax pour cup, which is the opening for pouring the molten bronze.
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These sprues become runways through which the metal flows and trapped air and gas escapes, allowing the bronze to flow to the bottom and also fill upward. 

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There are several variables to consider, giving importance to proper ventilation and shrinkage as the molten bronze flows and distributes throughout the cavities of the mold.

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The outcome of a good pour is critical, and depends largly on the science of gating and spruing.

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INVESTING

 

"Investment" is the next step of building a rock-hard shell around the wax sculpture. Later in the process, when the wax has been melted out, the investment will serve as a mold for the molten bronze.

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The ceramic shell technique begins by dipping the gated wax into vats of slurry followed immediately with a silica sand shower. This process builds a very thin wall of silica around the wax. 

When repeated approximately 9 or 10 times,  and allowing for drying time in between layers, a shell, about ½" thick, will form around the wax.

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The grain sizes vary from very fine in the layer closest to the wax, to very coarse on the outside layer. This process was originally developed by the aerospace industry, and is the same ceramic used for the tiles on the space shuttles.

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The wax is a "positive" which must disappear in order to create a cavity or "negative" for the bronze to fill, so the ceramic invested shells are fired in a kiln, the wax being melted or "lost" from the shell. Thus the phrase "lost wax casting" comes from this process. This will also harden the ceramic shell, making it suitable to accept the molten bronze.  

 

THE POUR

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A mixture of 95% copper, 4% silicon, and 1% maganeze has been created specifically for the art industry. This bronze formula is contained in a huge graphite crucible, and blasted in a natural gas furnace, melting at 1700°F. At the same time, the ceramic shell is heated in a kiln to approximately 1100°F, and then supported in a barrel filled with sand. The molten bronze is heated to 1,940 degrees, and is poured into a the hot shell. If it were poured into a coller, room temperature shell, the bronze liquid would "seize" and stop flowing if it become confronted with cold. Approximately one hour after the pour, the piece is cool enough to handle, and the devesting may begin in the next step.

Please feel free to contact Sculptor, Cathi Cook, with any questions.
Cathi Cook Sculpture Studio
1994 Dorset Drive  Fort Collins, CO 80526  Phone 970.493.8939 
cathi@cathicook.com

copyright 2003,2004,2005,2006,2007,2008. CathiCook  All Rights Reserved.